006 UNIT 036 Assembling and testing electronic circuits Learning outcomes 1 2 Know how to assemble and test electronic circuits Performance evidence must be the main form of evidence gathered. Candidates are required to demonstrate competence of all practical skills (outcome one) on three separate occasions and essential knowledge (outcome two) on at least one occasion. Outcome one 1 Work safely at all times, complying with health and safety legislation, regulations and other relevant guidelines. Continued on page 2 Unit 036 Assembling and testing electronic circuits 1
UNIT 036 Outcome one (CONTINUED) 2 Carry out all of the following during the electronic assembly and testing activities: adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations follow job instructions, assembly drawings and test procedures at all times ensure that the components are free from damage, dirt or other contamination prepare the electronic components for the assembly operations (such as pre-forming pins) use safe and approved techniques to mount the electronic components on the circuit boards check that the tools and test instruments are within calibration date and are in a safe and usable condition where appropriate, apply procedures and precautions to eliminate electrostatic discharge (ESD) hazards (such as the use of grounded wrist straps) follow clean work area protocols, where appropriate return all tools and equipment to the correct location on completion of the assembly activities. Continued on page 3 2 Level 2 NVQ Diploma in Performing Engineering Operations
Outcome one (CONTINUED) 3 Assemble one of the following circuit types: single-sided circuit flexible circuit thick film circuit double-sided circuit thin film circuit hybrid circuit. 4 Plan the electronic assembly, wiring and testing activities before you start them. 5 Use appropriate sources to obtain the required specifications, circuit diagrams, component assembly and test information. 6 Obtain the correct tools and equipment for the assembly and test operations, and check that they are in a safe and usable condition. 7 Assemble circuits using four of the following tools: heat shunts/tweezers snipe or long nosed pliers sleeving pliers component forming devices wire strippers side or end cutters bolt fasteners (screwdriver, spanners) anti-static packaging, mats and straps specialised assembly tools/ equipment. Continued on page 4 Unit 036 Assembling and testing electronic circuits 3
UNIT 036 Outcome one (CONTINUED) 8 Use the appropriate methods and techniques to assemble the components in their correct positions. 9 Assemble electronic components using two of the following: manual soldering techniques surface mount techniques mechanical fixing methods. Continued on page 5 4 Level 2 NVQ Diploma in Performing Engineering Operations
Outcome one (CONTINUED) 10 Assemble circuits to the required specification, to include using fifteen of the following types of component: fixed resistors variable resistors potentiometers sensing resistors (such as temperature or light operated) fixed capacitors variable capacitors electrolytic capacitors diodes Zener diodes light emitting diodes (LEDs) transistors thyristors thermistors analogue or digital integrated circuits surface mount packages rectifiers switches mini transformers decoders regulators encoders or resolvers inverters or servo controllers edge connectors wiring pins/tags/wire links fixing spacers insulators small heat sinks cables cable connectors protection devices opto-electronics/optical fibre components. Continued on page 6 Unit 036 Assembling and testing electronic circuits 5
UNIT 036 Outcome one (CONTINUED) 11 Assemble electronic components to produce five of the following types of circuit: audio amplifiers signal converters signal generators counter/timers oscillators filters microprocessor based applications comparators power amplifiers motor control regulated power supplies logic function controls display circuits other specific circuit sensor/actuator circuit (such as linear, rotational, temperature, photo-optic, flow, level, pressure) digital circuit (such as process control, microprocessor, logic devices, display devices) signal processing circuit (such as frequency modulating/ demodulating, amplifiers, filters) alarms and protection circuits ADC and DAC hybrid circuits. 12 Secure the components, using the specified connectors, securing devices and soldering techniques. 13 Wire and terminate cables to the appropriate connections on the circuit boards. 14 Use appropriate test methods and equipment to check that the completed assembly is safe and meets all aspects of the specification. Continued on page 7 6 Level 2 NVQ Diploma in Performing Engineering Operations
Outcome one (CONTINUED) 15 Carry out visual checks on the completed circuits, to include all of the following: soldered joints are clean, shiny, free from solder spikes, bridges, holes, excess solder and flux components are correctly mounted for best physical support, and are correctly orientated excess component leads have been trimmed off to the standard required circuit tracks are free from faults (such as lifting, breaks, bridges, hot spots) there are no obvious signs of damage, to components or to the substrate all required connectors, wire links, spacers and other ancillary items are in place. 16 Carry out visual checks on the completed circuits, to include all of the following: multimeter oscilloscope logic probe/clip logic analyser pulse sequencing analyser counter/timers signature analysers protocol analyser signal generator signal tracer stabilised power supplies measuring bridges software diagnostic programs data communications test set bus exerciser. Continued on page 8 Unit 036 Assembling and testing electronic circuits 7
UNIT 036 Outcome one (CONTINUED) 17 Carry out checks and adjustments, appropriate to the circuits being assembled, to include six of the following: logic states dc voltage/current levels ac voltage/current levels clock/timer switching oscillations attenuation pulse width/rise time open/short circuit resistance capacitance waveform analysis inductance frequency modulation/ demodulation amplification signal noise/interference levels. 18 Produce electronic circuits in accordance with one of the following: BS or ISO standards and procedures customer standards and requirements company standards and procedures other international standard. 19 Deal promptly and effectively with problems within your control, and seek help and guidance from the relevant people if you have problems that you cannot resolve. 20 Leave the work area in a safe and tidy condition on completion of the electronic assembly and testing activities. 8 Level 2 NVQ Diploma in Performing Engineering Operations
Outcome TWO Know how to assemble and test electronic circuits Knowledge required 1 Describe the specific safety practices and procedures that you need to observe when assembling and testing electronic circuits (including any specific legislation, regulations or codes of practice for the activities, equipment or materials). 2 Describe the hazards associated with assembling and testing electronic circuits (such as heat, toxic fumes, spilled/splashed chemicals/solder, static electricity, using sharp instruments for stripping cable insulation, connecting clips/probes into circuits), and how they can be minimised. 3 Describe the importance of wearing appropriate protective clothing and equipment, and keeping the work area safe and tidy. 4 Describe the precautions to be taken to prevent electrostatic discharge (ESD) damage to electronic circuits and components (such as use of earthed wrist straps, anti-static mats, special packaging and handling areas). 5 Explain how to use and extract information from circuit diagrams, block and schematic diagrams, equipment manuals, data sheets, test procedures and instructions (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken. 6 Describe the various types of circuit boards used (such as printed circuit boards, thin film, thick film and flexible film circuitry). 7 Explain how to recognise, read the values and identify polarity and any other orientation requirements for all electronic components being used in the assemblies (such as capacitors, resistors, inductors, diodes, transistors, integrated circuit chips, and other discrete through-hole or surface-mounted components). 8 Explain how to check that components meet the required specification/operating conditions (such as values, tolerance, current carrying capacity, voltage rating, power rating, working temperature range). Continued on page 10 Unit 036 Assembling and testing electronic circuits 9
UNIT 036 Outcome TWO (CONTINUED) Know how to assemble and test electronic circuits Knowledge required 9 Describe the basic principles of operation of the electronic circuits being assembled, and the purpose of the individual modules/components within the circuits. 10 Describe the application and use of circuit protection equipment (such as fuses and other overload protection devices). 11 Describe the preparation requirements for components to be used in the assembly (such as pre-forming component pins/legs). 12 Describe the methods of mounting and securing electronic components to various surfaces (such as the use of manual soldering techniques, surface mount technologies and mechanical fixing devices, use of heat sinks/shunts). 13 Describe the methods of attaching markers/labels to components or cables to assist with identification (such as colour coding conductors, using coded tabs). 14 Describe the use of BS7671/IEE wiring, and other regulations, when selecting wires and cables and when carrying out tests on electronic circuits. 15 Describe the importance of making visual checks of the completed assembly (such as examination for excessive solder or solder spikes which may allow short circuits to occur, correct orientation of components for pin configuration or polarity, obvious signs of damage (such as heat damage) or strain on terminations). 16 Describe the tools and equipment used in the electronic assembly activities (including the use of cable stripping tools, crimping tools, soldering irons, specialist assembly tools). 17 Describe the importance of ensuring that all tools are in a safe and serviceable condition, are used correctly and are returned to their correct location on completion of the assembly activities. 18 Describe the care, handling and application of electronic test and measuring instruments (such as multimeter, oscilloscope, signal generators, stabilised power supplies, logic probes/analyzers, measuring bridges). Continued on page 11 10 Level 2 NVQ Diploma in Performing Engineering Operations
Outcome TWO (CONTINUED) Know how to assemble and test electronic circuits Knowledge required 19 Explain how to check that test equipment is safe to use (such as condition of power cables, using suitably fused test probes, clips and leads); how to check that equipment is within current calibration approval dates; checking that the test equipment is suitable for the tests you are to carry out and can cover the range and values you are to measure. 20 Explain how to connect to an approved power supply and, where appropriate, signal source; identifying correct test points in the circuit; how to position test instruments into circuits without damaging circuit components (such as using test probes, ensuring correct polarity, taking antistatic precautions); setting instrument zero readings; obtaining instrument readings and comparing them with expected results. 21 Explain how to make adjustments to circuit components; making decisions on circuit performance and faulty components; removal and replacement of faulty components. 22 Describe the fault-finding techniques to be used when the equipment fails to operate correctly. 23 Explain when to act on your own initiative and when to seek help and advice from others. 24 Describe the importance of leaving the work area in a safe and clean condition on completion of the electronic assembly and testing activities (such as returning hand tools and test equipment to the designated location, cleaning the work area, removing and disposing of waste). Unit 036 Assembling and testing electronic circuits 11
UNIT 036 SIGN-OFF Candidate declaration I confirm that all the evidence submitted for this qualification is my own work. Signature of candidate: Date: Assessor declaration I can confirm that the evidence presented is valid, authentic, current and sufficient within the context of the qualification criteria and demonstrates the candidate s competence across the outcomes claimed. Signature of assessor: Name of assessor: Date: Internal verifier signature: Internal verifier name: Date: External verifier signature: External verifier name: Date: 12 Level 2 NVQ Diploma in Performing Engineering Operations